Seat assembly for a vehicle and a method of manufacturing the same

ABSTRACT

A seat assembly for a vehicle includes a support structure and a seat bottom mounted to the support structure. A seatback is coupled to the support structure and is rotatable about a longitudinal axis between a first collision position when applying a first force to the seatback and a second collision position when applying a second force to the seatback. A first energy absorbing member is mounted to the seat bottom for absorbing energy when the seatback rotates to the first collision position. A second energy absorbing member includes a first end coupled to the first energy absorbing member and a second end coupled to the seatback for absorbing energy when the seatback rotates to the second collision position after the first energy absorbing member absorbs energy in the first collision position.

CROSS REFERENCE TO RELATED APPLICATION

This application claims the benefit of U.S. Provisional Application No. 60/892,543 filed Mar. 2, 2007, and U.S. Provisional Application No. 60/966,403 filed Aug. 28, 2007, both of which are incorporated by reference.

BACKGROUND OF THE INVENTION

1. Field of the Invention

The subject invention generally relates to a seat assembly for a vehicle and a method of manufacturing the same.

2. Description of the Prior Art

School buses include a seat assembly for transporting passengers and more specifically, school buses incorporate several seat assemblies into the school bus in rows. The seat assembly includes a seat bottom extending generally horizontally and a seatback coupled to the seat bottom and extending generally vertically relative to the seat bottom. Typically, the passengers are free to move about the school bus without being restrained in the seat assembly. In other words, the passengers are not buckled into seatbelts to restrain movement of the passengers. In seat assemblies that do not include seatbelts, federal regulatory standards require that the seatback controllably collapse forward when the passenger seated behind pitches forward and strikes the seatback such that the seatback absorbs energy from the uncontrollably moving passenger. Such an arrangement is referred to in industry as compartmentalized seating. In such a configuration, the forward rotation of the seatback is unlimited.

Recently a longstanding debate as to whether school buses should be equipped with seatbelts has intensified, with those favoring seatbelt usage on the school buses now prevailing. As a result, more and more school buses are now being equipped with seatbelt assemblies. Public pressure is building to require all school buses be equipped with seatbelt assemblies. A strong consensus has already developed requiring the seatbelt assemblies include a lap/shoulder belt combination similar to designs now installed in most modern automobiles.

In such a configuration, the seatbelt assembly is mounted to the seatback and the seatback remains stationary relative to the school bus in order for the seatbelt to properly lock and restrain the passenger. However, in such a configuration, the benefits of the compartmentalized seating are lost, i.e., the seatback does not controllably collapse to absorb energy when a passenger pitches forward and strikes the seatback. Because school buses are often used to transport children, it is foreseeable that in a school bus equipped with seatbelt assemblies that some children will buckle their seatbelts while some other children will forget or refuse to buckle their seatbelts.

Accordingly, it would be advantageous to develop a seat assembly that absorbs energy when unbuckled passengers uncontrollably move forward and strike a seatback while also providing adequate support for the seatbelt assembly such that the seatbelt assembly properly functions when the passenger is buckled into the seatbelt.

SUMMARY OF THE INVENTION AND ADVANTAGES

The subject invention includes a seat assembly for a vehicle. The seat assembly comprises a support structure defining a longitudinal axis and a seat bottom mounted to the support structure and extending outwardly away from the support structure. The seat assembly further includes a seatback coupled to the support structure and rotatable about the longitudinal axis between a first collision position when applying a first force to the seatback and a second collision position when applying a second force to the seatback. A first energy absorbing member is mounted to one of the seat bottom and the seatback for absorbing energy when the seatback rotates to the first collision position during application of the first force. A second energy absorbing member has a first end coupled to the first energy absorbing member at one of the seat bottom and the seatback and a second end coupled to the other of the seat bottom and the seatback for absorbing energy when the seatback rotates to the second collision position during application of the second force after the first energy absorbing member absorbs energy in the first collision position.

The present invention also includes a seat assembly for a vehicle with the seat assembly comprising a support structure defining a longitudinal axis and a seat bottom mounted to the support structure and extending outwardly away from the support structure. The seat assembly further includes a seatback coupled to the support structure and being rotatable in a first direction about the longitudinal axis from an upright position to a first collision position when applying a first force to the seatback. The seatback is also rotatable in the first direction from the first collision position to a second collision position when applying a second force to the seatback. The seatback is also rotatable in a second direction opposite the first direction from the upright position to an inclined position when applying a third force to the seatback. The seatback assembly further includes a slot defined in one of the seat bottom and the seatback and extending transverse to the longitudinal axis from a first end portion to a second end portion spaced from each other with a middle portion disposed between the first and second end portions. A first energy absorbing member is mounted in the slot. A pin is disposed through the slot and is coupled to the other of the seat bottom and the seatback with the pin abutting the first energy absorbing member and disposed in the middle portion of the slot when the seatback is in the upright position. The pin is movable in the slot from the middle portion toward the first end portion of the slot during application of the first force to the seatback. The pin is also moveable in the slot from the middle portion to the first end portion of the slot and engages the first end portion during application of the second force to the seatback. The pin is moveable in the slot from the middle portion toward the second end portion of the slot during application of the third force to the seatback.

The subject invention also includes a method of manufacturing a seat assembly having a support structure defining a longitudinal axis, a seat bottom coupled to the support structure, a seatback coupled to the support structure and rotatable relative to the seat bottom about the longitudinal axis, a first energy absorbing member with one of the seat bottom and seatback defining a slot which houses the first energy absorbing member, and a second energy absorbing member having a first end connected to the first energy absorbing member and a second end connected to the other of the seat bottom and seatback. The method comprises coupling the seat bottom to the support structure. The method further includes rotatably coupling the seatback to the support structure in a flat position with the seatback and the seat bottom extending in a common plane. The method further includes mounting the first energy absorbing member in the slot of the one of the seat bottom and the seatback. The method further includes connecting the first end of the second energy absorbing member to the first energy absorbing member with the second end of the energy absorbing member free from the other of the seat bottom and seatback.

Therefore, the subject invention provides for a seat assembly having a first energy absorbing member and a second energy absorbing member for absorbing energy when a passenger uncontrollably moves forward and strikes a seatback. Thus, when the passengers are unrestrained in the seat assembly the first and second energy absorbing members absorb energy for reducing injury to the passengers. Further, the first energy absorbing member is designed to compress when applying a first force and a third force and uncompress when the first and third forces are not being applied, such that the first energy absorbing member returns to its original configuration. In other words, the first energy absorbing member is reusable in such situations.

In addition, when the passenger is fastened into the seat assembly with a seatbelt assembly, the seatback on which the passenger rests against must provide adequate support such that the seatbelt assembly locks and prevents the passenger from flying forward. However, some passengers may forget or refuse to be fastened into the seat assembly with the seatbelt assembly and can pitch forward when the vehicle is abruptly stopped. Thus, the first and second energy absorbing members are designed to absorb energy when the passenger uncontrollably strikes the seatback in front of the passenger while also providing a hard stop to allow the seatbelt assembly to function properly and maintain the seatback in the generally upright position.

The first and second energy absorbing members provide for varying energy absorption when a passenger uncontrollably moves forward and strikes a seatback in front of the passenger in response to an abrupt stop by the vehicle, e.g., during a collision. The varying energy absorption depend upon the magnitude of the force applied to the seatback by the uncontrollably moving passenger. In other words, if the passenger imparts the first force on the seatback, the seatback rotates to the first collision position. If the passenger imparts the second force on the seatback, the seatback rotates to the second collision position.

Further, because the second energy absorbing member is coupled to the first energy absorbing member, the first and second energy absorbing members act together to absorb different forces. In other words, the first energy absorbing device absorbs energy when the seatback rotates to the first collision position during application of the first force. The coupling of the second energy absorbing device to the first energy absorbing device allows the second energy absorbing device to absorb energy during application of the second force after the first energy absorbing device absorbs energy in the first collision position.

In addition, method allows for the seatbacks of several seat assemblies to be disposed in the flat position such that the several seat assemblies can be stacked upon each other. Such a configuration reduces the space required during shipping, thereby reducing costs associated with shipping. In addition, a stack of the seat assemblies is easily moved from one location to another, for example, with a fork truck, i.e., several seat assemblies can be easily transported as one unit.

BRIEF DESCRIPTION OF THE DRAWINGS

Other advantages of the present invention will be readily appreciated, as the same becomes better understood by reference to the following detailed description when considered in connection with the accompanying drawings wherein:

FIG. 1 is a perspective view of several seat assemblies mounted in rows to a floor of a vehicle;

FIG. 2 is a perspective view of the seat assembly including a seat bottom and a seatback;

FIG. 3 is a perspective view of a portion of the seat assembly to show a seat bottom frame and a seatback frame;

FIG. 4 is a cross-sectional view along line 3-3 of FIG. 3 when the seatback in an upright position;

FIG. 5 is a perspective view of the seat assembly with the seatback rotated to a flat position generally parallel to a seat bottom;

FIG. 6 is a perspective view of a portion of the seatback to show a back cover of the seatback and a bottom cover of the seat bottom;

FIG. 7 is a front view of a seatback frame with a plurality of seatbelt assemblies to the seatback frame;

FIG. 8 is a front view of the seat assembly configured in a two passenger configuration;

FIG. 9 is a front view of the seat assembly configured in a three passenger configuration;

FIG. 10 is a cross-sectional view along line 3-3 of FIG. 3 when the seatback in a first collision position;

FIG. 11 is a cross-sectional view along line 3-3 of FIG. 3 when the seatback in a second collision position;

FIG. 12 is a cross-sectional view along line 3-3 of FIG. 3 when the seatback in an inclined position;

FIG. 13 is a partially exploded perspective view of a portion of the seat assembly including a partial-cutaway view of the seatback frame; and

FIG. 14 is a side view of several seat assemblies disposed in the flat position and stacked upon each other.

DETAILED DESCRIPTION OF THE INVENTION

Referring to the Figures, wherein like numerals indicate like or corresponding parts throughout the several views, a seat assembly for a vehicle (not numbered) is generally shown at 20. Referring to FIG. 1, the seat assembly 20 can be disposed in a school bus for supporting one or more passengers. In such a configuration, several seat assemblies 20 are incorporated into the school bus in rows. It should be appreciated that the seat assembly 20 may be used in any type of vehicle including, for example, an automobile, an airplane, a train, and a boat.

Referring to FIGS. 2 and 3, the seat assembly 20 includes a support structure 22 defining a longitudinal axis L. Preferably, the support structure 22 defines a cylindrical configuration extending along the longitudinal axis L. In other words, the support structure 22 has a round cross-section about the longitudinal axis L.

A seat bottom 24 is mounted to the support structure 22 and extends outwardly away from the support structure 22. In other words, the seat bottom 24 extends generally horizontally. The seat bottom 24 includes a seat bottom frame 26 mounted to the support structure 22. The seat bottom frame 26 is typically formed of metal, such as, for example, steel or aluminum. However it is to be appreciated that the seat bottom frame 26 may be formed of any other suitable material capable of providing the necessary support and strength.

The seat bottom frame 26 includes a first column 28, a second column 30, and a third column 32 spaced from each other with each of the columns 28, 30, 32 mounted to the support structure 22. Each of the columns 28, 30, 32 extends outwardly away from the support structure 22, and more specifically, each of the columns 28, 30, 32 extends generally horizontally. A plurality of mounting pedestals 34 are mounted to the support platform 22 and extend downwardly and transverse to the longitudinal axis L for mounting the seat assembly 20 to a floor of the vehicle.

Referring to FIG. 6, the seat bottom 24 includes a bottom cover 36 disposed on the seat bottom frame 26. The bottom cover 36 may be formed of a single sheet of thermoformed plastic material. However it is to be appreciated that the bottom cover 36 may be formed of any other suitable material and may be formed by any suitable method. The seat bottom frame 26 can include a ramp 38 extending outwardly away from the support structure 22 for urging the passengers of the seat assembly 20 toward the support structure 22. The ramp 38 reduces the likelihood that the passengers uncontrollably move forward and strike the seat assembly 20 in front of the respective passenger when the vehicle stops abruptly, i.e., also referred to in industry as submarining. The ramp 38 increases in height as the ramp 38 extends in a direction away from the support structure 22.

A seatback 40 is coupled to the support structure 22 and is rotatable about the longitudinal axis L relative to the seat bottom 24, as will be discussed below. The seatback 40 may include a plurality of foam pillows (not shown) positioned to absorb energy in case the passenger uncontrollably move forward and strikes the seatback 40 in front of the respective passenger when the vehicle stops abruptly.

As best shown in FIGS. 3 and 7, the seatback 40 includes a seatback frame 42 coupled to the support structure 22 and rotatable about the longitudinal axis L. The seatback frame 42 is typically formed of metal, such as steel or aluminum. However it is to be appreciated that the seatback frame 42 may be formed of any other suitable material capable of providing the necessary support and strength.

The seatback frame 42 includes a first tower 44, a second tower 46, and a third tower 48 spaced from each other and coupled to the support structure 22. More specifically, the towers 44, 46, 48 are spaced at a predetermined distance from each other along the longitudinal axis L. For example, the first and second towers 44, 46 are spaced farther away from each other than the second and third towers 46, 48. However, it is appreciated that the towers 44, 46, 48 can be spaced at any interval relative to each other without departing from the nature of the present invention. The first column 28 of the seat bottom frame 26 is mounted to the support structure 22 adjacent the first tower 44, the second column 30 of the seat bottom frame 26 is mounted to the support structure 22 adjacent the second tower 46, and the third column 32 of the seat bottom frame 26 is mounted to the support structure 22 adjacent the third tower 48. In other words, each of the columns 28, 30, 32 aligns with one of the respective towers 44, 46, 48.

Each of the towers 44, 46, 48 defines a hole 50 complementary in configuration to the round cross-section of the support structure 22 for coupling each of the towers 44, 46, 48 to the support structure 22. Such a configuration allows for rotation of the towers 44, 46, 48 about the longitudinal axis L. In other words, the support structure 22 and the hole 50 of each of the towers 44, 46, 48 are sized such that the towers 44, 46, 48 are rotatable about the support structure 22. It is to be appreciated that the configuration of the support structure 22 and the hole 50 may be any suitable configuration for allowing each of the towers 44, 46, 48 to rotate about the support structure 22.

Each tower 44, 46, 48 has at least one extension extending outwardly away from the seatback. The at least one extension is further defined as a first extension 52 and a second extension 54 spaced from the first extension 52. It is also appreciated that the seatback frame 42 may have any configuration in the alternative to the towers 44, 46, 48 described herein without departing from the nature of the present invention.

Referring to FIG. 6, the seatback 40 further includes a back cover 56 disposed over the seatback frame 42. The back cover 56 is typically hollow and receives each of the towers 44, 46, 48 such that the towers 44, 46, 48 rotate simultaneously about the longitudinal axis L. The back cover 56 structurally reinforces the seatback frame 42. Specifically, the back cover 56 ties the towers 44, 46, 48 together for reinforcing the seatback 40. The back cover 56 is typically formed by injection molding and is typically formed of a plastic material. However it is to be appreciated that the back cover 56 may be formed of any suitable material and formed by any suitable method.

As best shown in FIGS. 2 and 5, the seat assembly 20 may include upholstery attached to the seatback 40 and/or the seat bottom 24. For example, the upholstery includes fabric and J-clips attached to the fabric. In such a configuration, the J-clips attach to the back cover 56 of the seatback 40 and/or attach to the bottom cover 36 of the seat bottom 24. As such, the upholstery is removeable from the seat assembly 20 by disconnecting the J-clips from the back cover 56 and/or the bottom cover 36.

Referring to FIG. 7, the seat assembly 20 further includes a plurality of seatbelt assemblies 58 coupled to the seatback 40. The seatbelt assemblies 58 and the seatback 40 are configurable for use by either two larger passengers in a two passenger configuration or three smaller passengers in a three passenger configuration. The two passenger configuration is shown in FIG. 8 and the three passenger configuration is shown in FIG. 9. The hardware of each of the seatbelt assemblies 58, for example, may include such components as a retractor 60, a belt 62 extendable from the retractor 60, a shoulder retainer (not numbered) receiving the belt 62, a belt height adjuster (not numbered) coupled to the shoulder retainer, and a clip 64 coupled to the belt 62. The belt height adjuster is also referred to in industry as an adjustable turning loop. As will be apparent from the description below and the figures, the seatbelt assemblies 58 are those which are commonly referred to “three-point seatbelt assemblies,” i.e., when restraining a passenger, the belt 62 extends from the passenger's shoulder, across the passenger's torso to one side of the passenger's lap, and across the passenger's lap to the other side of the passenger's lap. In such a configuration, the seatbelt assembly 58 is fixed at three points: the passenger's shoulder, one side of the passenger's lap, and the other side of the passenger's lap.

The seatbelt assemblies 58 also include a plurality of buckles 66 coupled to the support structure 22 for receiving the clips 64. The clips 64 and the buckles 66 can be coded and/or keyed to assist the passengers in properly pairing the clips 64 and the buckles 66 for the two passenger configuration or the three passenger configuration. The clips 64 and buckles 66 may be visually coded, such as color coding, printed text, indicia or any other suitable coding.

Each of the towers further defines a channel 68 extending transverse to the longitudinal axis L. Specifically, each of the towers 44, 46, 48 has a generally U-shaped cross-section. One retractor 60 is disposed in the channel 68 of each of the towers 44, 46, 48. As such, the belt 62 extends upwardly from the retractor 60 to the shoulder retainer within the channel 68. Such a configuration reduces or eliminates lateral forces exerted on the respective towers 44, 46, 48 when the seatbelt assemblies 58 lock and retain the passenger during an abrupt or hard stop by the vehicle. Because the lateral forces are reduced or eliminated, the size of the towers 44, 46, 48 may be reduced which is advantageous with respect to cost to manufacture and packaging.

As best shown in FIGS. 3, 4, and 10-13, at least one of the seat bottom 24 and the seatback 40 defines a slot 70 extending transverse to the longitudinal axis L. In the configuration shown in the figures, the seat bottom 24 defines the slot 70. The slot 70 includes a first end portion 72 and a second end portion 74 facing each other in a spaced relationship. The slot 70 includes a middle portion 76 disposed between the first and second end portions 72, 74. The middle portion 76 is defined by an upper surface 78 and a lower surface 80 facing each other in a spaced relationship. The upper and lower surfaces 78, 80 extend from the first end portion 72 to the second end portion 74. Preferably the slot 70 has an oval configuration. However it is to be appreciated that the slot 70 may be of a circular configuration, a rectangular configuration, a square configuration or any other suitable configuration. As best shown in FIG. 13, the slot 70 is further defined as a plurality of slots 70 with each of the columns 28, 30, 32 of the seat bottom frame 26 defining one of the slots 70.

As best shown in FIGS. 3, 4 and 10-13, the seat assembly 20 includes an energy absorbing device. As described below, the energy absorbing device selectively allows the seatback 40 to rotate relative to the seat bottom 24.

The seatback 40 on which the passenger rests against must provide adequate support such that the seatbelt assembly 58 locks and restrains the passenger against the seat bottom 24 and the seatback 40. In other words, when the vehicle abruptly stops, the passenger's momentum urges the passenger forward and the passenger must move forward relative to the seatback 40 in order for the seatbelt assembly 58 to lock and prevent the belt 62 from extending from the retractor 60. The energy absorbing device limits the rotation of the seatback 40 about the longitudinal axis L, i.e., provides a hard stop, in order for the seatbelt assembly 58 to properly function and stop the passenger from uncontrollably moving forward. However, some passengers may refuse or forget to buckle their seatbelt assembly 58, i.e., engage the clip 64 in the buckle 66 with the belt 62 extending across the passenger. In such a situation, when the vehicle is abruptly stopped, the passenger may uncontrollably move forward and strike the seatback 40 in front of the passenger. The energy absorbing device allows the limited rotation of the seatback 40 about the longitudinal axis L to absorb energy from such passengers. Thus, the energy absorbing device absorbs energy when the passenger uncontrollably strikes the seatback in front of the passenger while also providing a hard stop to allow the seatbelt assembly 58 to function properly.

The seatback 40 is shown in the upright position in FIG. 4. As shown in FIG. 10, the seatback 40 is rotatable in a first direction about the longitudinal axis L from the upright position to a first collision position when applying a first force F1 to the seatback 40. The first force F1 is represented by an arrow in FIG. 10. The first force F1 can be, for example, a result of a passenger uncontrollably moving forward and striking the seatback 40 in front of the passenger. As shown in FIG. 11, the seatback 40 is also rotatable in the first direction about the longitudinal axis L to a second collision position when applying a second force F2 to the seatback 40. The second force F2 is represented by an arrow in FIG. 11. The second force F2 can be, for example, a result of a passenger uncontrollably moving forward and striking the seatback 40 in front of the passenger. As described further below, it is appreciated that the term “first force” and the term “second force” are used to delineate between forces of different magnitude. The second force F2 is greater than the first force F1. As shown in FIGS. 10 and 11, both the first force F1 and the second force F2 act in the same direction on the seatback 40. It should be appreciated that FIGS. 4 and 10-12 are illustrative of varying positions of the seatback 40 and all of the details of the seat assembly 20 are not shown, e.g., the back cover 56, the bottom cover, and the seatbelt assembly 58.

It is to be appreciated that the seatback 40 extends generally vertically relative to the seat bottom 24 when in the upright position. The seatback 40 includes a front surface 82 and a back surface 84 opposing each other. The seatback 40 is rotatable to the first and second collision positions when applying the first and second forces F1, F2, respectively, to the back surface 84.

In addition, the seatback 40 is rotatable to an inclined position in response to a third force F3, as shown in FIG. 12. Specifically, the seatback 40 is rotatable in a second direction opposite the first direction when applying the third force F3 to the seatback. The third force F3 is represented by an arrow in FIG. 12. The third force F3 can be, for example, a result of a passenger leaning back against the seatback 40 during a rear-end collision of the vehicle. It is to be appreciated that the first and second forces F1, F2 may be applied anywhere along the back surface 84 and the third force F3 may be applied anywhere along the front surface 82.

The energy absorbing device includes a first energy absorbing member 86 mounted to one of the seat bottom 24 and the seatback 40 for absorbing energy when the seatback 40 rotates to the first collision position during application of the first force F1. Specifically, the first energy absorbing member 86 is mounted in the slot 70 of one of the seat bottom 24 and the seatback 40 for absorbing energy. As shown in the figures, the first energy absorbing member 86 is mounted in the slot 70 of the seat bottom 24. The first energy absorbing member 86 is typically press fit into the slot 70 and abuts the first and second end portions 72, 74 and the upper and lower surfaces 78, 80 of the slot 70. However it is to be appreciated that the first energy absorbing member 86 may be mounted to the slot 70 in any suitable manner. As best shown in FIG. 3, the first energy absorbing member 86 is further defined as a plurality of first energy absorbing members 86 with one of each of the first energy absorbing members 86 mounted to each of the columns 28, 30, 32 of the seat bottom frame 26.

The first energy absorbing member 86 is typically formed of an elastomeric material. For example, the first energy absorbing member 86 is formed of a thermoplastic elastomeric material, such as a thermoplastic polyester elastomeric material, e.g., that available under the trade name Hytrel® which is commercially available from E. I. du Pont de Nemours and Company. As discussed below, the elastomeric material allows the first energy absorbing member 86 to elastically compress when applying the first and third forces F1, F3 to the seatback 40 and to uncompress when the first and third forces F1, F3 are released, i.e., the first energy absorbing member 86 returns to its original configuration. The first energy absorbing member 86 is reusable in such situations. The first energy absorbing member 86 may also be referred to as a bushing.

The energy absorbing device also includes a second energy absorbing member 88 having a first end 90 connected to the first energy absorbing member 86 and a second end 92 coupled to one of the seat bottom 24 and the seatback 40. In the configuration shown in the figures, the second end 92 of the second energy absorbing member 88 is connected to the seatback 40. The second energy absorbing member 88 is moveable with the seatback 40 when the seatback 40 rotates to the first and second collision positions and the inclined position. As discussed below, because the first end 90 of the second energy absorbing member 88 is connected to the first energy absorbing member 86, movement of the second energy absorbing member 88 in response to rotation of the seatback 40 results in compression of the first energy absorbing member 86. The second energy absorbing member 88 is further defined as a plurality of second energy absorbing members 88 with one of each of the second energy absorbing members 88 attached to each of the towers 44, 46, 48 and coupled to each of the first energy absorbing members 86.

In the configuration shown in the figures, the second energy absorbing member 88 is an elongated strap. The second energy absorbing member 88 acts as a linkage that maintains the seatback 40 in the upright position when no external force is being applied to the seatback 40. It should be appreciated that the linkage may be defined as a bar, a shaft or any suitable connector for coupling the first energy absorbing member 86 to the seatback 40 such that the first energy absorbing member 86 absorbs energy when the seatback 40 rotates about the longitudinal axis.

The first energy absorbing member 86 defines an aperture 94 through the middle portion 76 of the slot 70 when the seatback 40 is in the upright position. The energy absorbing device further includes a pin 96 disposed in the slot 70. Specifically, the pin 96 is connected to the first end 90 of the second energy absorbing member 88 and extends into the aperture 94 of the first energy absorbing member 86. The pin 96 abuts the first energy absorbing member 86. The pin 96 is further defined as a plurality of pins 96 with one of the pins 96 disposed through each of the first energy absorbing members 86 and attached to the second end 92 of each of the second energy absorbing members 88.

The pin 96 is movable in the slot 70 toward the first end portion 72 of the slot 70 during application of the first and second forces F1, F2 to the back surface 84 of the seatback 40. The pin 96 is also moveable in the slot 70 toward the second end portion 74 when applying the third force F3 to the front surface 82. The first energy absorbing 86 member elastically compresses to absorb energy when the pin 96 moves toward the first and second end portions 72, 74 of the slot 70 as the seatback 40 rotates to the first collision position and the inclined position, respectively.

The second energy absorbing member 88 is typically formed of metal such as, for example, steel. In such a configuration, the steel is, for example, ⅜ inches thick. However it is to be appreciated that the second energy absorbing member 88 may have various thicknesses and widths as known to those of ordinary skill in the art. For example, as the thickness of the second energy absorbing member 88 increases, the width of the second energy absorbing member 88 may decrease. As another example, as the width of the second energy absorbing member 88 increases, the thickness of the second energy absorbing member 88 may decrease.

The second energy absorbing member 88 defines at least one bend 98 disposed between the first and second ends 90, 92 with the bend 98 maintaining a predetermined configuration when the seatback 40 rotates to the first collision position. As discussed below, the bend 98 deforms when the seatback 40 rotates to the second collision position for absorbing energy. In other words, the bend 98 maintains the predetermined configuration when the seatback 40 rotates in the first direction to the first collision position. Once the bend 98 deforms when in the second collision position, a hard stop is created for preventing additional rotation of the seatback 40 about the longitudinal axis L which allows the seatbelt assembly 58 to lock, i.e. function properly. Specifically, the bend 98 deforms such that the second energy absorbing member 88 is straight to prevent further rotation of the seatback 40. It is to be appreciated that the bend 98 may be in any configuration for absorbing energy, such as a kink, a plurality of bends, etc. It is to be further appreciated that the second energy absorbing member 88 may be any suitable energy absorbing member without departing from the nature of the subject invention.

The first energy absorbing member 86 has a rigidity and the second energy absorbing member 88 has a rigidity greater than the rigidity of the first energy absorbing member 86. As such, the first energy absorbing member 86 absorbs energy when the seatback 40 moves to the first collision position and the second energy absorbing member 88 absorbs energy when the seatback 40 moves to the second collision position.

The pin 96 is typically rigidly attached to the first end 90 of the second energy absorbing member 88. In such a configuration, movement of the second energy absorbing member 88 in response to rotation of the seatback 40 causes the pin 96 to rotate within the slot 70. It is to be appreciated that the second energy absorbing member 88 may be mounted to the pin 96 such that the pin 96 does not rotate within the slot 70 during movement of the second energy absorbing member 88.

A rod 97 extends between the first and second extensions 52, 54 of each respective tower 44, 46, 48. The second energy absorbing member 88 is attached to the first and second extensions 52, 54 of each of the towers 44, 46, 48. The rod 97 is disposed through the second end 92 of the second energy absorbing member 88 with the rod 97 attached to the first and second extensions 52, 54. It should be appreciated that the second energy absorbing member 88 may be connected to the extension 52, 54, for example, by bolting or pinning the second end to the extension 52, 54.

For illustrative purposes, a discussion of the seatback 40 moving from the upright position to the first and second collision positions and the inclined position with the corresponding movement of the first and second energy absorbing members 86, 88 is set forth below. Only one set of the first and second energy absorbing members 86, 88 are shown in FIGS. 4 and 10-12, however it is to be appreciated that this discussion applies to each of the first and second energy absorbing members 86, 88 coupled to each of the towers 44, 46, 48. Referring to FIG. 4, when no forces are applied to the seatback 40, the seatback 40 is disposed in the upright position and the pin 96 is at rest and disposed along the middle portion 76 of the respective slot 70.

Referring to FIG. 10, the first force F1 is applied to the back surface 84 of the seatback 40, which rotates the seatback 40 about the longitudinal axis L toward the seat bottom 24 to the first collision position. The first and second extensions 52, 54 of the tower 44, 46, 48 rotate away from the seat bottom 24 which causes the first energy absorbing member 88 to move with the towers 44, 46, 48. The pin 96 moves in the respective slot 70 toward the first end portion 72 to compress the first energy absorbing member 86 between the pin 96 and the first end portion 72 of the slot 70. It is to be appreciated that the pin 96 may move downwardly toward the lower surface 80 of the slot 70 as the pin 96 moves toward the first end portion 72 due to the first energy absorbing member 88 angling away from the seat bottom 24. It is to be further appreciated that the pin 96 may move upwardly toward the upper surface of the slot 70 as the pin 96 moves toward the first end portion 72 in a configuration where the first energy absorbing member 88 angles upwardly toward the seat bottom 24. The pin 96 compresses the respective first energy absorbing member 86 for absorbing energy without the second energy absorbing member 88 absorbing energy, i.e., the first energy absorbing member 86 is compressed and the second energy absorbing member 88 does not deform. When the first force F1 is released, the first energy absorbing member 86 uncompresses and moves the pin 96 back to the middle portion 76 while the seatback 40 returns to the upright position.

Referring to FIG. 11, the second force F2 is applied to the back surface 84 of the seatback 40 which rotates the seatback 40 about the longitudinal axis L toward the seat bottom 24 to the second collision position. The second force F2 rotates the seatback 40 closer to the seat bottom 24 than when the first force F1 is applied. In other words, the seatback 40 moves through the first collision position to the second collision position. The first and second extensions 52, 54 of the respective tower 44, 46, 48 rotate away from the seat bottom 24 which causes the second energy absorbing member 88 to move with the tower 44, 46, 48. The pin 96 moves in the respective slot 70 toward the first end portion 72 of the slot 70 to the first position. The pin 96 compresses the respective first energy absorbing member 86 between the pin 96 and the first end portion 72 of the slot 70 for absorbing energy. As the pin 96 continues to move, the first energy absorbing member 86 is frangible and the pin 96 breaks through the first energy absorbing member 86 such that the pin 96 abuts or engages the first end portion 72 when in the second position. It is to be appreciated that the first energy absorbing member 86 absorbs energy as the pin 96 breaks through the first energy absorbing member 86. However, once the pin 96 engages the first end portion 72, the first energy absorbing member 86 does not absorb more energy. When the pin 96 engages the first end portion 72 in the second collision position, the bend 98 in the second energy absorbing member 88 deforms or straightens out for absorbing additional energy. Once the bend 98 deforms, a hard stop is created for preventing additional rotation of the seatback 40 about the longitudinal axis L which allows the seatbelt assembly 58 to lock, i.e. function properly. When the second force F2 is eliminated, the first and second energy absorbing members 86, 88 are typically replaced with new first and second energy absorbing members 86, 88. It is to be appreciated that the seat assembly may be replaced with a new seat assembly 20 when the second force F2 is applied.

Referring to FIG. 12, the third force F3 is applied to the front surface 82 of the seatback 40 which rotates the seatback 40 about the longitudinal axis away from the seat bottom 24 to the inclined position. As discussed above, the seatback 40 rotates in the first direction when moving from the upright position to the first and second collision positions and the seatback 40 rotates in the second direction opposite the first direction when moving from the upright position to the inclined position. The first and second extensions 52, 54 of the respective tower 44, 46, 48 rotate toward the seat bottom 24 which causes the second energy absorbing member 88 to move with the respective tower 44, 46, 48. The pin 96 moves in the respective slot 70 toward the second end portion 74 of the slot 70 to compress the first energy absorbing member 86 between the pin 96 and the second end portion 74. The pin 96 compresses the respective first energy absorbing member 86 for absorbing energy without the second energy absorbing member 88 absorbing energy, i.e., the first energy absorbing member 86 is compressed and the second energy absorbing member 88 does not deform. When the third force F3 is released, the first energy absorbing member 86 uncompresses and moves the pin 96 back to the middle portion while the seatback 40 returns to the upright position.

Referring to FIGS. 5 and 14, the seatback 40 is capable of being disposed in a flat position for shipping prior to mounting into the vehicle. In the flat position, the seatback 40 and the seat bottom 24 extend in a common plane and several seat assemblies 20 can be stacked upon each other. In such a configuration, during shipping, the second energy absorbing member 88 is coupled to the first energy absorbing member 86 with the second end 92 of the second energy absorbing member 88 is free from the seatback 40, i.e., not connected to the extensions 52, 54 of seatback 40 with the rod 97. Specifically, the first end 90 of each of the second energy absorbing members 88 are attached to respective pins with each of the pins 96 disposed through the respective aperture 94 of the first energy absorbing members 86 without attaching the second end 92 of the second energy absorbing members 88 to the extensions 52, 54 of the respective tower 44, 46, 48. When the seat assembly 20 is prepared to be installed in the vehicle, the seatback 40 is rotated to the upright position and the second end 92 of the second energy absorbing member 88 is connected to the extensions 52, 54.

The subject invention also provides a method of manufacturing the seat assembly 20. The method includes coupling the seat bottom 24 to the support structure 22. The method further includes rotatably coupling the seatback 40 to the support structure 22 in the flat position with the seatback 40 and the seat bottom 24 extending in the common plane. It is appreciated that the seatback 40 may be moved in any position relative to the seat bottom 24 during the coupling of the seatback 40 to the seat bottom 24 and when the coupling is complete, the seatback 40 is in the flat position.

The method further includes mounting the first energy absorbing member 86 in the slot 70 of the one of the seat bottom 24 and the seatback 40. As discussed above, the first energy absorbing member 86 is shown in the figures as being mounted to the seat bottom 24. As discussed above, the first energy absorbing member 86 may be press-fit into the slot 70. In such a configuration, the method further includes press-fitting the first energy absorbing member 86 into the slot 70.

The method further includes connecting the first end 90 of the second energy absorbing member 88 to the first energy absorbing member 86 with the second end 92 of the energy absorbing member free from the other of the seat bottom 24 and seatback 40, i.e., that which the first energy absorbing member 86 is not mounted to. Specifically, in the configuration shown in the figures where the first energy absorbing member 86 is mounted to the seat bottom 24, the first end 90 of the second energy absorbing member 88 is connected to seatback 40. The second end 92 of the second energy absorbing member 88 is “free” in the sense that the second energy absorbing member 88 is not connected to the extension of the respective tower 44, 46, 48 with the rod 97. It is appreciated that when the second end 92 of the second energy absorbing member 88 is “free,” the second energy absorbing member 88 can still be restrained to prevent rotation of the second energy absorbing member 88 relative to the seat bottom 24 or the seatback 40. For example, the second energy absorbing member 88 can be tied to one of the seat bottom 24 and the seatback 40 to prevent rotation in such a configuration.

The method, more specifically, includes the step of disposing the pin 96 through the slot 70 with the first end of the second energy absorbing member 88 attached to the pin 96. Specifically, the step of disposing the pin 96 through the slot 70 is further defined as disposing the pin 96 through the aperture 94 of the first energy absorbing member 86.

The seatback 40 is rotated to the upright position and the second end of the second energy absorbing member 88 is attached to the seatback 40 to support the seatback 40 in the upright position. Specifically, the method includes attaching the second end 92 of the second energy absorbing member 88 to the extension 52, 54 of the seatback 40 to support the seatback 40 in the upright position. More specifically, the rod 97 is extended through the second end of the second energy absorbing strap and through the extensions 52, 54 of the respective tower 44, 46, 48. It should be appreciated that in the configuration where the seat assembly 20 includes a plurality of first and second energy absorbing member 86, 88, when the seatback 40 is rotated to the upright position the steps set forth above are performed for each of the first and second energy absorbing member 86, 88.

The method of the present invention is advantageous in that several seat assemblies 20 can be stacked upon each other as shown in FIG. 14. Such a configuration reduces the space required during shipping, commonly referred to as “air space,” thereby reducing costs associated with shipping. In addition, a stack of the seat assemblies 20 is easily moved from one location to another, for example, with a fork truck, i.e., several seat assemblies 20 can be easily transported as one unit. Further, the method allows for the seatback 40 to be assembled from the flat position to the upright position in a quick and easy manner.

Obviously, many modifications and variations of the present invention are possible in light of the above teachings. The foregoing invention has been described in accordance with the relevant legal standards; thus, the description is exemplary rather than limiting in nature. Variations and modifications to the disclosed embodiment may become apparent to those skilled in the art and do come within the scope of the invention. Accordingly, the scope of legal protection afforded this invention can only be determined by studying the following claims. 

1. A seat assembly for a vehicle, said seat assembly comprising: a support structure defining a longitudinal axis; a seat bottom mounted to said support structure and extending outwardly away from said support structure; a seatback coupled to said support structure and rotatable about said longitudinal axis between a first collision position when applying a first force to said seatback and a second collision position when applying a second force to said seatback; a first energy absorbing member mounted to one of said seat bottom and said seatback for absorbing energy when said seatback rotates to said first collision position during application of said first force; and a second energy absorbing member having a first end coupled to said first energy absorbing member at said one of said seat bottom and said seatback and a second end coupled to the other of said seat bottom and said seatback for absorbing energy when said seatback rotates to said second collision position during application of said second force after said first energy absorbing member absorbs energy in said first collision position.
 2. The seat assembly as set forth in claim 1 wherein said first end of said second energy absorbing member moves relative to said one of said seat bottom and said support platform as said seatback rotates about said longitudinal axis.
 3. The seat assembly as set forth in claim 2 wherein said first energy absorbing member is elastically compressible as said first end of said second energy absorbing member moves in response to rotation of said seatback from an upright position to said first collision position.
 4. The seat assembly as set forth in claim 3 wherein said first energy absorbing member is frangible as said first end of said second energy absorbing member moves in response to rotation of said seatback from said first collision position to said second collision position.
 5. The seat assembly as set forth in claim 2 wherein said one of said seat bottom and said seatback defines a slot extending transverse to said longitudinal axis from a first end portion to a second end portion with said first energy absorbing member mounted in said slot between said first and second end portions.
 6. The seat assembly as set forth in claim 5 wherein said first energy absorbing member is compressed between said first end of said second energy absorbing member and said one of said first and second end portions of said slot when said seatback rotates relative to said seat bottom.
 7. The seat assembly as set forth in claim 5 wherein said first energy absorbing member defines an aperture and wherein said second energy absorbing member includes a pin extending from said first end of said first energy absorbing member and into said aperture.
 8. The seat assembly as set forth in claim 7 wherein said pin elastically compresses said first energy absorbing member between said pin and said one of said first and second end portions of said slot when said seatback rotates to said first collision position and wherein said pin breaks said first energy absorbing member and contacts said one of said first and second end portions when said seatback rotates to said second collision position.
 9. The seat assembly as set forth in claim 7 wherein said pin is spaced from said first and second end portions when said seatback is in an upright position and wherein said pin is moveable toward said one of said first and second end portions when said seatback rotates in a first direction from said upright position to said first collision position and wherein said pin is moveable toward the other of said first and second end portions when said seatback rotates in a second direction opposite of said first direction from said upright position to a reclined position.
 10. The seat assembly as set forth in claim 2 wherein said second energy absorbing member is rigid between said first energy absorbing member and the other of said seat bottom and said seatback when said seatback is in an upright position
 11. The seat assembly as set forth in claim 10 wherein said second energy absorbing member is rigid as said seatback rotates from said upright position to said first collision position and is plastically deformable as said seatback rotates from said first collision position to said second collision position.
 12. The seat assembly as set forth in claim 11 wherein said one of said seat bottom and said seatback defines a slot extending transverse to said longitudinal axis from a first end portion to a second end portion with said first energy absorbing member mounted in said slot between said first and second end portions.
 13. The seat assembly as set forth in claim 12 wherein said second energy absorbing member includes a pin extending into said slot with said pin spaced from said first and second end portions when said seatback is in said upright position and with said pin contacting one of said first and second end portions when said seatback is in said second collision position.
 14. The seat assembly as set forth in claim 11 wherein said second energy absorbing member defines a bend between said first and second ends with said second energy absorbing member being rigid at said bend as said seatback rotates from said upright position to said first collision position and with said second energy absorbing member plastically deforming at said bend as said seatback rotates from said first collision position to said second collision position.
 15. The seat assembly as set forth in claim 14 wherein said second energy absorbing member is straight after said bend is plastically deformed in said second collision position to prevent further rotation of said seatback in said first direction beyond said second collision position.
 16. The seat assembly as set forth in claim 10 wherein said seatback includes at least one tower coupled to said support structure presenting an extension extending downwardly from said support structure with said second end of said second energy absorbing member coupled to said extension.
 17. The seat assembly as set forth in claim 2 wherein said one of said seat bottom and said seatback defines a slot extending transverse to said longitudinal axis from a first end portion to a second end portion with said first energy absorbing member mounted in said slot between said first and second end portions and wherein said second energy absorbing member compresses said first energy absorbing member between said second energy absorbing member and one of said first and second end portions when said seatback rotates from an upright position to said first collision position and wherein said second energy absorbing member breaks said first energy absorbing member, contacts said one of said first and second end portions, and plastically deforms when said seatback rotates from said first collision position to said second collision position.
 18. The seat assembly as set forth in claim 1 wherein said first energy absorbing member is formed of an elastomeric material.
 19. The seat assembly as set forth in claim 1 wherein said first energy absorbing member is mounted to said seat bottom and said second end of said second energy absorbing member is attached to said seatback with said second energy absorbing member moveable with said seatback when said seatback rotates about said longitudinal axis.
 20. The seat assembly as set forth in 1 wherein said seat bottom includes a ramp extending upwardly for urging passengers toward said seatback.
 21. The seat assembly as set forth in claim 1 further including a seatbelt coupled to said seatback for restraining a passenger against said seat bottom and said seatback as said seatback rotates from said first and second collision positions.
 22. A seat assembly for a vehicle, said seat assembly comprising: a support structure defining a longitudinal axis; a seat bottom mounted to said support structure and extending outwardly away from said support structure; a seatback coupled to said support structure and being rotatable in a first direction about said longitudinal axis from an upright position to a first collision position when applying a first force to said seatback, said seatback being rotatable in said first direction from said first collision position to a second collision position when applying a second force to said seatback, and said seatback being rotatable in a second direction opposite said first direction from said upright position to an inclined position when applying a third force to said seatback; a slot defined in one of said seat bottom and said seatback and extending transverse to said longitudinal axis from a first end portion to a second end portion spaced from each other with a middle portion disposed between said first and second end portions; a first energy absorbing member mounted in said slot; and a pin disposed through said slot and coupled to the other of said seat bottom and said seatback with said pin abutting said first energy absorbing member and disposed in said middle portion of said slot when said seatback is in said upright position, said pin being movable in said slot from said middle portion toward said first end portion of said slot during application of said first force to said seatback, said pin being moveable in said slot from said middle portion to said first end portion of said slot and engaging said first end portion during application of said second force to said seatback, and said pin being moveable in said slot from said middle portion toward said second end portion of said slot during application of said third force to said seatback.
 23. The seat assembly as set forth in claim 22 wherein said seat bottom defines said slot with said pin coupled to said seatback such that said pin moves with said seatback as said seatback rotates about said longitudinal axis.
 24. The seat assembly as set forth in claim 22 wherein said first energy absorbing member abuts and extends between said first and second end portions.
 25. The seat assembly as set forth in claim 22 wherein said first energy absorbing member defines an aperture through said middle portion of said slot with said pin extending through said aperture.
 26. The seat assembly as set forth in claim 22 wherein said first energy absorbing member is formed of an elastomeric material.
 27. The seat assembly as set forth in claim 22 further including a linkage mounted to the other of said seat bottom and said seatback and extending to said pin and mounted to said pin such that rotation of said seatback about said longitudinal axis moves said linkage relative to said seatback and moves said pin in said slot.
 28. The seat assembly as set forth in claim 27 wherein said slot is defined in said seat bottom and said linkage is mounted to said seatback.
 29. The seat assembly as set forth in claim 27 wherein said linkage is further defined as a second energy absorbing member for absorbing energy as said seatback rotates about said longitudinal axis.
 30. The seat assembly as set forth in claim 22 wherein said pin elastically compresses said first energy absorbing member between said pin and said first end portion of said slot as said seatback rotates from said upright position to said inclined position and wherein said pin elastically compresses said first energy absorbing member between said pin and said second end portion of said slot as said seatback rotates from said upright position to said first collision position and wherein said pin breaks said first energy absorbing member as said seatback rotates from said upright position to said second collision position.
 31. A method of manufacturing a seat assembly having a support structure defining a longitudinal axis, a seat bottom coupled to the support structure, a seatback coupled to the support structure and rotatable relative to the seat bottom about the longitudinal axis, a first energy absorbing member with one of the seat bottom and seatback defining a slot which houses the first energy absorbing member, and a second energy absorbing member having a first end connected to the first energy absorbing member and a second end connected to the other of the seat bottom and the seatback, said method comprising: coupling the seat bottom to the support structure; rotatably coupling the seatback to the support structure in a flat position with the seatback and the seat bottom extending in a common plane; mounting the first energy absorbing member in the slot of the one of the seat bottom and the seatback; and connecting the first end of the second energy absorbing member to the first energy absorbing member with the second end of the energy absorbing member free from the other of the seat bottom and seatback.
 32. The method as set forth in claim 31 further including rotating the seatback relative to the seat bottom about the longitudinal axis to an upright position with the seatback extending transverse to the seat bottom.
 33. The method as set forth in claim 32 further including connecting the second end of the second energy absorbing member to the other of the seat bottom and the seatback.
 34. The method as set forth in claim 33 wherein the seat bottom defines the slot and the second end of the second energy absorbing member is connected to the seatback and wherein mounting the first energy absorbing member is further defined as mounting the first energy absorbing member in the slot of the seat bottom and wherein connecting the second end of the second energy absorbing member is further defined as connecting the second end to the seatback.
 35. The method as set forth in claim 31 wherein mounting the first energy absorbing member is further defined as press-fitting the first energy absorbing member into the slot.
 36. The method as set forth in claim 31 wherein the first energy absorbing member defines an aperture and the second energy absorbing member includes a pin at the first end of the second energy absorbing member and wherein connecting the first end is further defined as inserting the pin through the aperture. 